Enhancing Infrastructure

Maintenance, repair and

upgrade of pressure vessels

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Reactors <

Coke Drums <

Alkylation Units <

High-Pressure Separators <

Digesters <

www.azz.com/wsi-europe
Engineered solutions are being demanded more and more
to increase product yields and improve plant operational
reliability. With our Unifuse® technology, AZZ WSI® can
deliver a repair and/or upgrade a wide range of pressure
vessels such as distillation units, reactors, coke drums,
digesters and high-pressure separators.

AZZ WSI repair on a Distillation Unit

With European headquarters in Hellevoetsluis, The Netherlands,
we are dedicated to providing safe, efficient and timely services
to our customers. We understand the complexity and technical
demands of the Refining market with unrivaled knowledge and
expertise gained over 30 years.
There are many potential problems affecting vessels such as wall
thinning, pitting, cracking and corrosion/erosion issues. Due to our
The largest global automated repair provider
There are a number of vital challenges that the industry faces. Each problem requires an individual solution that is based on our extensive
refinery experience gained in all regions of the world, as shown in the table below.
Challenges
Extend operational lifespan and enhance
asset performance
Improve asset mechanical integrity
Reduce maintenance costs
Consistent quality according to standards
Issues in challenging materials, locations,
geometries and environments
Meeting turnaround safety requirements
Reduced inspection demands
automated weld overlay technology, AZZ WSI offers a repair
or upgrade that can be implemented quickly and lasts forever.
We also work closely with our customers in the petrochemical,
chemical and the pulp and paper industries, helping them to
anticipate and react to challenges quickly, and provide tailored
solutions that precisely match their requirements.
Solutions
We solve the cause of the problem with a permanent repair, thus
avoiding the need for replacement by utilizing our automated weld
overlay repair solution.
Reinforce, upgrade or structurally repair an asset, combining our
proven engineering and implementation experience with our
automated weld overlay technology.
Permanent, long-term repair adjusted to expected operational
conditions could mean less maintenance (spot repairs) required in
subsequent outages. We have the capacity to respond to short lead
times, tight schedules and have a 24/7 manufacturing capability.
Quality assurance and control comes as standard in all our solutions,
with ASME and EN certifications for our automated welding and
fully trained, specialist workforce.
We offer total engineering support that includes tooling design,
metallurgical consultation, Finite Element Analysis (FEA), welding
process design, and mock-up capabilities.
Attention and commitment to HSE standards is one of our core
values and drives all our projects and solutions, as well as our
leadership and teams during each stage of a project.
Permanent, expertly repaired surface solutions reduce the
maintenance time required for inspections as the number
of spot repairs are reduced.
3
 Failure mode of the asset
Assets function in hostile operating environments and, combined with the need to reduce the environmental impact of production,
this increases the corrosion and erosion of process equipment, and critical boiler, drum and vessel components.

A range of common failures affects the reliability of the asset and the safe operation of the plant.

Common failures Observed damage

Corrosion Reduction of pressure boundary thickness/wall thinning

Sulfate corrosion Pressure boundary surface damage/pitting
Naphthenic acid corrosion Base metal contamination
HCl and HF corrosion Sub-surface cracking
Ammine corrosion Boundary weld cracking
Corrosion under insulation Skirt attachment cracking
Localized cracking
Stress Corrosion Cracking (SCC) Base metal damage
Chloride/alkaline/ammonia/sulfide SCC Structural instability/bulges
Hydrogen-induced cracking (HIC) Localized accelerated corrosion

Cyclic stress
Low-cycle thermal fatigue
Vessel skirt stress risers
Penetration-related stress risers

Uncontrolled event
Localized fire
Environmental damage
Uncontrolled process excursions

Bulging Full circumferential skirt cracks Corrosion/Erosion

We have proven products, experienced personnel and high-quality systems that deliver the definitive solution to these observed damages.
In particular, Unifuse technology is central to the successful, long-lasting repair of essential customer assets throughout the Energy
industry worldwide.

4
The AZZ WSI Unifuse process
AZZ WSI has over 30 years’ experience in the protection of vessels using the Unifuse technology.

We utilize Unifuse automated welding technology to structurally repair, upgrade and reinforce assets to deliver long-term, reliable
performance, which is a key objective for the mechanical integrity of critical refinery components.

Automated weld overlay using the Unifuse process Radial residual stress prediction

Horizontal weld overlay results in a low dilution that is critical

for the success of corrosion protection of the overlay. Other
characteristics of this process are a small heat-affected zone and
minimal distortion.

Comparing our horizontal process with the vertical down practice,

specifically for pressure vessel application, the horizontal method
avoids the higher – and localized – heat input that results in higher
temperature gradients during the cooling phase of the weld process.
Smooth surface finish
Therefore, it is possible to avoid the typically high risk of localized
buckling in the shell due to the combination of a localized great
heat input and the axial compressive stress developed from external Homogenous overlay <7% dilution
loads (structural loads) acting on the vessel at the time of welding.
Fusion boundary <10 – 12% dilution
A horizontal weld overlay applied along the 360° area of a vessel
results in a homogeneous heat input and, therefore, in a lower
temperature gradient and minimal distortion risk.

The Unifuse process enables us to increase wall thickness to Base material

restore the pressure boundary and to apply an improved metallurgy
to reduce the effects of erosion and corrosion, thereby delivering
consistent quality by assuring the lowest dilution and distortion Schematic illustration of a cross-section
possible. This process also allows customers to control their
schedule by keeping occupational risk as low as possible.

5
 Project assessment
The first stage of the process is to perform a complete assessment
of the challenges faced by the customer. We provide a detailed
evaluation of the situation, taking into account the customer’s
desired end result for safety, schedule and quality. This thorough
assessment, performed by our world-class teams, enables us to
propose the most suitable and efficient solution for the customer,
beginning with an engineering evaluation completed by our
corrosion metallurgists and welding engineers.
Shaded plot of vacuum column predicted Mock-up for automatic weld overlay
diametric shrinkage
The Health, Safety and Environment plan
Workforce is fully equipped with necessary safety materials
6
Engineering
Our engineering department offers a complete range of analysis,
including distortion mitigation, stress evaluation, structural stability,
and special welding procedures to assure optimal performance at
all times. Our qualified tooling metallurgical, corrosion and welding
engineers strive to determine the most suitable technical solutions for
our customers. At all times, we observe the strictest requirements
for safety, project schedules and quality, whether we perform an FEA
to predict and minimize the distortion associated with our welding
process or demonstrate an innovative process by means of a mock-up.
Working on
various levels
Ventilation plan
Scaffolding
High safety level
Pre-process evaluation
A detailed plan covering all health, safety and environment issues
supports everything we do from analysis to implementation.
Total compliance with Health, Safety and Environment (HSE)
standards is fundamental to all our operations. We base all our
training, procedures, onsite activities and manufacturing processes
on adhering to the strictest HSE standards. AZZ WSI is certified
to SCC Petrochemical and we are renowned for maintaining the
highest safety standards in the industry today.
Our qualified HSE Supervisors evaluate the scope of work to ensure
that our planning anticipates and reduces risk as much as possible
and that implementation is carried out in accordance with all the
applicable safety rules. Our safety plan includes a full risk assessment
that reflects the appropriate certifications, planning, responsibilities,
training and the task risk analysis.
Pre-job site inspections
We take care to deliver all services to a high level of safety, quality
and in the agreed time. Our projects are executed using highly
experienced, trained and certified personnel at all levels, from site
managers to welders.

During the evaluation phase of the project, we normally perform a

pre-job site visit with key implementation and technical personnel,
which helps us to clarify the best solution from a practical viewpoint
with the various parties involved. This enables us to confirm that
the best solution has been offered and gives a better vision of the
actual site situation and how to further optimize our execution plan
and schedule.
Pre-job site inspection

Our highly experienced QA inspectors (Level II and III)

help us to verify the actual project scope, and work
together with our site managers to ensure that we
provide the best solution possible.

Dye penetrant inspection

7
 Automated weld overlay on site
Following the results of our comprehensive analysis, inspections
and safety planning, we then implement the various types of welding
procedures to solve the customer’s specific problem, as described in
the following sections. This methodical process results in our ability
to provide the best solution for the customer’s particular asset failure.
In case there is existing cladding or weld overlay on the vessel, this
needs to be carefully removed by the gouging process. Automated
weld overlay allows for the application of a consistent layer of new
metal, fully fused to the original base material. Wall thickness can
be restored (build-up) for structural reinforcement and the unit
material can be upgraded for consistent corrosion resistance.

Corrosion-resistant weld overlay

Unifuse weld overlay for both build-up and corrosion resistance

 ur automated process has the ability to recover thickness lost by weld build-up and
O
can also be applied to provide an appropriate material upgrade for a localized corrosion
problem by assuring a high-quality deposit. Our primary focus is to provide permanent
repair solutions that solve the root cause of the problem and extend the operational
lifespan of the asset.

Weld overlay on spheres and domes

Overlay on an overhead position

We lead the industry in the enhancement of the mechanical integrity even if the repair
is in an overhead position. Crucially, we have the capability to operate safely in some
of the most inaccessible areas, such as domes and spheres. This industry-leading
expertise ensures a high-quality build-up and corrosion-resistant weld overlay.

Nozzle overlay
Onsite automated nozzle repair

 ith our fully automated technology, we offer solutions for corrosion issues in nozzles
W
from 24 inches down to 2 inches in diameter, delivering the same high-quality deposit,
thus avoiding expensive replacement costs.

Orbital welding
Repair of through-wall cracks in head to shell circumferential welds

Our orbital welding capabilities, combined with a narrow groove preparation, allows us to
perform a high-quality welding joint on assets such as pipes, pigtails, and tube replacement
in a relatively short schedule. Orbital welding allows us to control all parameters to
achieve a high-quality, flawless joint, especially for thick-section components.

Structural reinforcement
Including tapering for avoiding further stress

We offer structural repair of components and reinforce assets to extend the asset
lifetime. Adding a tailored, designed structural reinforcement can successfully repair
cracks, welding seams and other mechanical damage resulting from fatigue.

8
 Quality Assurance
Once the welding program has been completed, we perform a
post-inspection to ensure that the quality of work has been carried Our inspectors produce a comprehensive report
out to the highest industry standards as agreed with the customer. of the completed work.

Our rigorous Quality Assurance (QA) program determines the Our typical report includes the following
highest standards for all welding procedures and also ensures Non Destructive Testing (NDT) activities
maximum quality levels are achieved throughout the entire project. performed by our onsite QA managers

UT, VT prior to overlay

90° Random during overlay application
B
A
UT, VT, PMI and PT after completion of overlay
C
90° Out-of-roundness prior to overlay and after overlay completion
D A
B
C 30° 75°
E
9*250

D F
G 30° 75°
E
0° 180° WSI craftsmen are qualified to EN 287-1 and EN ISO
All AZZ
9*250

0° 60°
F H

+7200H
G I
J
0° 60° 0° 180° 14732 or ASME and the work scopes are performed in accordance
+7200
I
J
Feedpipe #11
with the requirements of PED 97/23/CE and applicable design and
Manway
@270
Feedpipe #11
manufacturing codes for pressure equipment.
Manway
@270

270° We have a Quality Assurance Program certified to EN-ISO 3834-3,

270°
AD-Merkblatt HP0 (TRB 200), TRD 201 and ASME U & S.

All welding procedures meet the requirements of EN-ISO 15614-1

Example of out-of-roundness evaluation and 7 and/or EN 288 and TÜV Merkblatt 1156/1166 or ASME BPVC.

PMI/FN inspection using XRF

Weld overlay PT inspection Thickness measurement

9
AZZ WSI develops and delivers specialized maintenance
through automated weld repair solutions, combined with
advanced technologies, engineering capabilities, and equipment.
Whether it is a solution for the upgrade of a coke drum,
vacuum crude tower, column, alkylation unit, reactor tube,
high-pressure separator, digester or cat cracker, we have the
commitment and proven industry track record to meet and
resolve the most difficult mechanical integrity challenges.

AZZ WSI repair on a Digester

Optimal protection
for digesters
To protect digesters, alloys such as 309 and 312 steel have been
successfully used for more than 30 years. Our Unifuse patented
process for applying 309 and 312 alloys allows us to achieve a weld
overlay free of solidification cracks. This process is typically applied
horizontally, thereby assuring a constant Cr concentration (typically
>25%) across the overlay. In addition, the old cladding must be
removed by means of gouging.

When schedule is crucial

The vertical down welding process is much faster than the horizontal
process, though there is a high heat input and temperature gradient
related to this process; therefore, there is a high risk of dilution and
possible distortion.

However, our engineering department can carefully design an

appropriate vertical down process by taking into consideration
different factors such as wall thickness, ambient conditions, and
heat sinks (insulation vs. natural/forced convection) to avoid this
associated risk and deliver a better schedule whilst keeping the AZZ WSI offers a unique, fully automated repair solution for the Nozzle ID
quality as high as possible. covering a range from 2 to 24 inches

Welding overlay vs. other solutions

There are many different methods used to repair damaged mechanical components. Above all, the decision criteria will define the method chosen.

Unifuse Total Section Strip/sheet

weld overlay replacement replacement lining

Nominal thickness recovery (build-up) + + + -

Material upgrade (corrosion protection) + + + +

Structural reinforcement + + + -

Lifetime extension + + + -

Maintaining schedule + - - -

Low safety risk + - - +

Emergency response + - - +

Inspection accuracy + + + -

Long lead time + - - +

Heavy lifting needed - + + -

Pressure test mandatory - + + -

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Enhancing Infrastructure

AZZ WSI® is a specialized global services company offering

innovative maintenance through automatic weld repair
solutions that extend the lifetime and maximize the
value of our customers’ assets in the Energy industry.

AZZ WSI B.V.

Marconiweg 16
3225 LV Hellevoetsluis
The Netherlands

T: +31 88 27 84 539
E: wsi-europe@azz.com
www.azz.com/wsi-europe WSI 111-0914EN